The Welding Handbook for Maritime Welders

5/27/2018 The Welding Handbook for Maritime Welders

1/552

for maritime welders

The Welding Handbook


2/552

Maritime

Welding HandbookWelding and

Related Processesfor Repair and Maintenance

Onboard

11th editionRevision 0

Notice: All welding is carried out on the welders own risk and account. Welding should be executed by a qualified and experiencedwelder and adequate safety measures should always be adhered to. The information and guidelines in this Welding Handbook are basedon general information and knowledge at hand and are believed to be accurate and reliable, but the information and guidelines are not

to be taken as a gua ran tee or war ran ty for a spe cia l pur pos e. The inf orm ati on and gui del ines are pro vid ed to the wel der sol ely for hisown consideration, and Wilhelmsen Ships Service AS assumes no legal responsibility or liability for eventual damages and/or losses

should the information and/or guidelines turn out to be incorrect or un-suitable. Wilhelmsen Ships Service AS is not liable for any loss ordamages whatsoever and howsoever arising which is due to force majeure, other events beyond the reasonable control of Wilhelmsen

Ships Service AS or events that could not reasonably be foreseen by Wilhelmsen Ships Service AS when this Welding Handbook wasmade. Wilhelmsen Ships Service AS is in no event liable for indirect, incidental or consequential damages or losses, including dam-

ages for loss of profits, resulting from lack of conformity, including but not limited to loss resulting from goods or software not workingwhen connected to other goods/software or for any related cause thereto. Wilhelmsen Ships Service ASs liability shall in any event

not exceed the total purchase price of theWilhelmsen Ships Service AS goods used during the welding operations. These conditionsare automatically accepted by anybody using the information and guidelines in this Welding Handbook.


3/552

2

INTRODUCTION

A ship at sea depends upon the knowledge, skills and self-reliance of the crew to carryout necessary maintenance and repair work. One of the important skills required is agood command of modern welding techniques.

The purpose of the Welding Handbook for maritime welders is to provide guidancein modern welding and related processes and to provide the welder with a source ofpractical information on the right solution to specific onboard welding problems.

Experience gained from user contact and welding training of crewmembers showed thatdocumentation aimed specifically at on board welding solutions was needed. This ledto the development of the first welding handbook for on-board repair and maintenancewelding already the 1950es.

This edition of the Welding Handbook builds upon all the earlier editions and onWilhelmsen Ships Services business activity.

Wilhelmsen Ships Service AS enjoys close co-operation with its customers andwould like to thank the many who have taken the effort to contribute with examples ofsuccessful solutions to real life maintenance situations.

Unitors business activitytraces back to 1905 andthe company NAG withAcetylene production as

a basic activity. The firstmaritime deliveries fromthis period were supplyof Acetylene as fuelgas for the guiding lightbeams from numerouslighthouses along thelong and weather-beaten coast of Norway.

The focus changedtowards gas and arc welding techniques when these were developed to useful

production and repair methods through the 1930es.

A main objective became to develop and maintain a range of welding equipment thatis suitable for onboard welding, backed by a worldwide service network, training anddocumentation.

In 1943 the company name was changed to UNITOR. Mergers and increasing activityin the department for sales to ships led to the establishment of this department as aseparate company; Unitor Ships Service AS in 1968.

In 2005 the company was bought by Wilh.Wilhelmsen ASA and the brand Unitor is nowincorporated in Wilhelmsen Ships Service AS, a part of Wilhelmsen Maritime ServicesAS, a company in the Wilh. Wilhelmsen Group


4/552

1.00

3

UNITOR WELDING HANDBOOK

9

2.01 Introduction & quick guides to processes 35

2.02 Filler material consumption 47

2.03 Metal identification 50

2.04 Unalloyed / low alloyed steel 55

2.05 Problem steels 62

2.06 Stainless steels 65

2.07 Cast iron 78

2.08 Copper and copper alloys 104

2.09 Aluminium 112

2.10 Evaluation of welds 114

3.01 Coated Electrodes 125

3.02 Tig Welding Rods & Fluxes 199

3.03 Wires for Wire Welding 217

3.04 Gas Welding Rods & Fluxes 241

3.05 Brazing Rods & Fluces 251

3.06 Cold Repair Compounds 277

4.01 Electrode welding & gouging 333

4.02 Tig Welding 381

4.03 Wire Welding 403

4.04 Plasma Cutting 441

4.05 Current Distribution System 455

5.01 AC/OX cutting, welding, brazing 459

5.02 Gas Supplies and gas distribution system 511

529

1 SAFETY IN WELDING

2 SOLUTIONS

3 CONSUMABLES

4 ARC WELDING ANDCUTTING PROCESS

& EQUIPMENT

5 GAS WELDING ANDCUTTING PROCESS &

EQUIPMENT

2.01

2.02

2.03

2.04

2.05

2.06

2.07

2.08

2.09

2.10

3.01

3.02

3.03

3.04

3.05

3.06

4.01

4.02

4.03

4.04

4.05

5.01

5.02

6 MISCELLANEOUS INFORMATION 6.00


5/552


4

1 SAFETY IN WELDING . . . . . . . . . . . . . . . . . . . . 9

1.01 Introduction . . . . . . . . . . . . . . . . . . . . . . . . 10

1.02 How to use the handbook . . . . . . . . . . . . 11 1.03 Welding instructions and training . . . . 12

1.04 Personal protection . . . . . . . . . . . . . . . . . 13

1.04.01 Arc welding face shields . . . . . 14

1.04.02 Protective goggles . . . . . . . . . . . 18

1.04.03 Welder's protective clothing . . 20

1.05 Work site protection . . . . . . . . . . . . . . . . 22

1.05.01 Welding curtain . . . . . . . . . . . . . . 22

1.05.02 Welding blanket . . . . . . . . . . . . . 22

1.05.03 Fire extinguisher . . . . . . . . . . . . . 23

1.06 Welding fumes . . . . . . . . . . . . . . . . . . . . . 24

1.06.01 Welding fumes . . . . . . . . . . . . . . 26

1.06.02 Fume extraction . . . . . . . . . . . . . 28

1.07 Safety check list . . . . . . . . . . . . . . . . . . . 30

1.07.01 Equipment . . . . . . . . . . . . . . . . . . 30

1.07.02 Work place . . . . . . . . . . . . . . . . . . 31

1.07.03 Hot work procedure . . . . . . . . . . 32

1.07.04 Operator protection . . . . . . . . . . 32

2 SOLUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.01 Introduction . . . . . . . . . . . . . . . . . . . . . . . . 36

2.01.01 Quick reference for cutting . . . 3 9

2.01.02 Quick reference for joining . . . . 40

2.01.03 Quick reference for rebuilding,hardfacing and coating . . . . . . . 43

2.01.04 Quick reference tocold repairs . . . . . . . . . . . . . . . . . 45

2.02 Filler material consumption . . . . . . . . . . 47

2.03 Metal identification . . . . . . . . . . . . . . . . . 50 2.04 Unalloyed / low alloyed steel . . . . . . . . 55

2.04.01 Introduction . . . . . . . . . . . . . . . . . 55

2.04.02 Unalloyed steel . . . . . . . . . . . . . . 55

2.04.03 Low alloyed steel . . . . . . . . . . . . 55

2.04.04 Heat resistant steel . . . . . . . . . . 55

2.04.05 Low temperature steel . . . . . . . . 56

2.04.06 Weathering steel . . . . . . . . . . . . 56

2.05 Problem steels . . . . . . . . . . . . . . . . . . . . . 62

2.06 Stainless steels . . . . . . . . . . . . . . . . . . . . 65

2.06.01 Introduction . . . . . . . . . . . . . . . . . 65

2.06.02 Austenitic Stainless Steel . . . . . 66

2.06.03 Ferritic Stainless Steel . . . . . . . . 68

2.06.04 Martensitic Stainless Steel . . . . 69

2.06.05 Duplex Stainless Steel . . . . . . . . 70

2.06.06 Clad Steel . . . . . . . . . . . . . . . . . . . 71

2.06.07 Stainless Steel corrosion types 72

2.06.08 Storing and handling of Stainless Steel onboard . . . . . . 74

2.06.09 Grinding/cutting consumablesfor Stainless Steel . . . . . . . . . . . 75

2.07 Cast iron . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

2.07.01 Introduction . . . . . . . . . . . . . . . . . 78

2.07.02 Grey cast iron . . . . . . . . . . . . . . . 79 2.07.03 White cast iron . . . . . . . . . . . . . . 80

2.07.04 Malleable cast iron . . . . . . . . . . 80

2.07.05 Ductile cast iron . . . . . . . . . . . . . 81

2.07.06 High alloy cast iron . . . . . . . . . . 82

2.07.07 Identification of cast iron . . . . . 83

2.07.08 Preparation of the work piece . . . . . . . . . . . . . . . . . . 84

2.07.09 Arc welding of cast iron . . . . . . 87

2.07.10 Braze welding of cast iron . . . . 95

2.07.11 Cold repair on cast iron . . . . . . . 97

2.08 Copper and copper alloys . . . . . . . . . . . 104

2.08.01 Introduction . . . . . . . . . . . . . . . . . 104

2.08.02 Brass . . . . . . . . . . . . . . . . . . . . . . . 104

2.08.03 Aluminium brass (Yorcalbro) . . 105

2.08.04 Bronze . . . . . . . . . . . . . . . . . . . . . . 106

2.08.05 Nickel bronses (Cunifer) . . . . . . 107

2.09 Aluminium . . . . . . . . . . . . . . . . . . . . . . . . 112

2.10 Evaluation of welds . . . . . . . . . . . . . . . . . 114

2.10.01 Typical welding faults . . . . . . . . 114 2.10.02 Inspection of welded joints . . . 118

2.10.03 Crack detection . . . . . . . . . . . . . . 123

3 CONSUMABLES . . . . . . . . . . . . . . . . . . . . . . . . . 125

3.01 Coated Electrodes . . . . . . . . . . . . . . . . . . 126

3.01.01 Introduction . . . . . . . . . . . . . . . . . 127

3.01.02 Types of electrodes . . . . . . . . . . 128

3.01.03 Storing and re-drying . . . . . . . . . 134

3.01.04 Classification and approvals . . 140

3.01.05 Welding positions . . . . . . . . . . . . 148


6/552


5

3.01.23 NIFE-334 N Nickel Iron Electrode for

Cast Iron . . . . . . . . . . . . . . . . . . . . 184

3.01.24 NICKEL-333 N Nickel Electrode for Cast Iron 186

3.01.25 TINBRO-341 Electrode for Copper Alloys . . . 188

3.01.26 ALBRONZE-344 Electrode for Copper Alloys . . . 190

3.01.27 ALUMIN-351 N Electrode for Aluminum . . . . . . . 192

3.01.28 CH-2-382 Electrode for Chamfering . . . . . 194

3.01.29 ACA-384 Electrode for Air Carbon ArcG o u g i n g . . . . . . . . . . . . . . . . . . . . 1 9 6

3.02 Tig welding rods and fluxes . . . . . . . . . 199

3.02.01 Introduction . . . . . . . . . . . . . . . . . 200

3.02.02 Classification . . . . . . . . . . . . . . . . 201

3.02.03 IMS-210 . . . . . . . . . . . . . . . . . . . . 202

3.02.04 ICROMO-216 . . . . . . . . . . . . . . . . 204

3.02.05 18/8 Mo-221 . . . . . . . . . . . . . . . . . 206

3.02.06 IDUPLEX-222 . . . . . . . . . . . . . . . . 208

3.02.07 ICUNI-30-239 . . . . . . . . . . . . . . . . 210

3.02.08 IALBRO . . . . . . . . . . . . . . . . . . . . . 212

3.02.09 I-FLUX-238 PF . . . . . . . . . . . . . . . 214

3.03 Wires for Wire Welding . . . . . . . . . . . . . 217

3.03.01 Introduction . . . . . . . . . . . . . . . . . 218

3.03.02 Classification . . . . . . . . . . . . . . . . 219

3.03.03 Storage and handling forFlux Cored wires . . . . . . . . . . . . . 221

3.03.04 GPS-W-200 . . . . . . . . . . . . . . . . . . 222

3.03.05 HST-SF-203 . . . . . . . . . . . . . . . . . . 224

3.03.06 HST-SF-232 . . . . . . . . . . . . . . . . . . 226

3.03.07 S 316 M-GF-221 . . . . . . . . . . . . . . 228

3.03.08 S 309 M-GF-222 . . . . . . . . . . . . . . 230

3.03.09 Icuni-W-239 . . . . . . . . . . . . . . . . . 232

3.03.10 Ialbro-W-237 . . . . . . . . . . . . . . . . 234

3.03.11 Alumag-W-235 . . . . . . . . . . . . . . . 236

3.03.12 Abratech-W-230 . . . . . . . . . . . . . 238

3.04 Gas Welding Rods & Fluxes . . . . . . . . . 241

3.04.01 Introduction . . . . . . . . . . . . . . . . . 242

3.01.06 GPO-302 NGeneral Purpose ElectrodeFor Mild Steel . . . . . . . . . . . . . . . 150

3.01.07 GPR-300H High Recovery Electrode

for Mild Steel . . . . . . . . . . . . . . . . 152

3.01.08 SPECIAL-303 N Double Coated Electrode for

Mild and Ship Quality Steel . . . . 154

3.01.09 LH-314 N Low Hydrogen Electrode for

Ship Quality Steel . . . . . . . . . . . . 156

3.01.10 LHH-314

High Recovery Low HydrogenElectrode for Ship Quality Steel 158

3.01.11 LHV-316 N Vertical Down Welding Low

Hydrogen Electrode forShip Quality Steel . . . . . . . . . . . . 160

3.01.12 LHT-318 N Electrode for High Temperature

Steel . . . . . . . . . . . . . . . . . . . . . . . 162

3.01.13 LHL-319 N Electrode for Low Temperature

Steel . . . . . . . . . . . . . . . . . . . . . . . 164

3.01.14 LHR-320 N Electrode for Weathering Steel 166

3.01.15 TENSILE-328 N Electrode for Difficult-to-

Weld Steel . . . . . . . . . . . . . . . . . . 168

3.01.16 IMPACT-329 S Electrode for Heat Resistant

Overlays . . . . . . . . . . . . . . . . . . . . 170

3.01.17 WEARMAX-327

Electrode for Joining & WearResistant Overlays . . . . . . . . . . . 172

3.01.18 ABRATECH-330 Electrode for abrasive wear . . . 174

3.01.19 18/8-321 N Electrode for Stainless Steel . . 176

3.01.20 23/14-322 N Electrode for Stainless Steel . . 178

3.01.21 DUPLEX-325 N Electrode for Duplex Steel . . . . 180

3.01.22 PICKLING GEL Pickling Gel for Stainless Steel 182


7/552


6

3.04.02 MS-200 . . . . . . . . . . . . . . . . . . . . . 244

3.04.03 Alumag-235 . . . . . . . . . . . . . . . . . 246

3.04.04 Aluflux-234 F . . . . . . . . . . . . . . . . 248

3.05 Brazing Rods & Fluxes . . . . . . . . . . . . . . 251

3.05.01 Introduction . . . . . . . . . . . . . . . . . 252

3.05.02 Bronze-264 . . . . . . . . . . . . . . . . . . 256

3.05.03 FC-Bronze-261 . . . . . . . . . . . . . . . 258

3.05.04 FC-Wearbro-262 . . . . . . . . . . . . . 260

3.05.05 FC-Cast Iron-268 . . . . . . . . . . . . . 262

3.05.06 AG-45-253 . . . . . . . . . . . . . . . . . . . 264

3.05.07 AG-60-252 . . . . . . . . . . . . . . . . . . . 266

3.05.08 Tin-240 . . . . . . . . . . . . . . . . . . . . . . 268

3.05.09 Fluxes for Brazing . . . . . . . . . . . . 270

3.05.10 Bronze Flux-261 PF . . . . . . . . . . . 271

3.05.11 Wearbro Flux-262 PF . . . . . . . . . 272

3.05.12 AG-60/45 Flux-252 PF . . . . . . . . . 273

3.05.13 Albro Flux-263 PF . . . . . . . . . . . . 274

3.06 Cold Repair Compounds . . . . . . . . . . . . . 277

3.06.01 Introduction . . . . . . . . . . . . . . . . . 278

3.06.02 Typical application areas . . . . . 278

3.06.03 How do Polymers work? . . . . . . 280

3.06.04 How to prepare the surface . . . 281 3.06.05 How to apply the product . . . . . 282

3.06.06 Polymer Kit-A . . . . . . . . . . . . . . . 284

3.06.07 Product overview . . . . . . . . . . . . 286

3.06.08 Leak Stop - Pipe repair . . . . . . . 288

3.06.09 Metalgrade Ready-Stick . . . . . . 292

3.06.10 Metalgrade Express . . . . . . . . . . 296

3.06.11 Metalgrade Rebuild . . . . . . . . . . 298

3.06.12 Metalgrade Hi-Temp . . . . . . . . . 304

3.06.13 Aquagrade Rebuild . . . . . . . . . . . 308

3.06.14 Ceramigrade Rebuild . . . . . . . . . 312

3.06.15 Ceramigrade Liner . . . . . . . . . . . 316

3.06.16 Ceramigrade Abrashield . . . . . . 320

3.06.17 Rubbergrade 6 Rebuild . . . . . . . 324

3.06.18 Rubbergrade 6 Remould . . . . . . 328

4 ARC WELDING AND CUTTNG PROCESS &E Q U I P M E N T . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 3

4.01 Electrode welding & gouging . . . . . . . . 335

4.01.01 Introduction . . . . . . . . . . . . . . . . . 336 4.01.02 Basic principles . . . . . . . . . . . . . 339

4.01.03 Power source characteristics . 340

4.01.04 Selecting power source . . . . . . 342

4.01.05 UWI-150 Autoline . . . . . . . . . . . . 344

4.01.06 UWI-201 . . . . . . . . . . . . . . . . . . . . 348

4.01.07 UWR-303 . . . . . . . . . . . . . . . . . . . . 350

4.01.08 UWI-400 . . . . . . . . . . . . . . . . . . . . 352

4.01.09 UWR-852 . . . . . . . . . . . . . . . . . . . . 358

4.01.10 Primary extension cables . . . . . 359

4.01.11 Secondary cables . . . . . . . . . . . . 360

4.01.12 Electrode holders, cable connectors & return

clamp assembly . . . . . . . . . . . . . 363

4.01.13 Accessories . . . . . . . . . . . . . . . . . 370 4.01.14 Welding techniques . . . . . . . . . . 371

4.01.15 Edge preparation . . . . . . . . . . . . 373

4.01.16 Electrodes for electrodewelding & gouging . . . . . . . . . . . 374

4.01.17 Air Carbon arc gouging . . . . . . . 377

4.02 Tig Welding . . . . . . . . . . . . . . . . . . . . . . . . 381

4.02.01 Introduction . . . . . . . . . . . . . . . . . 382

4.02.02 Basic principles . . . . . . . . . . . . . 383

4.02.03 Shielding gas . . . . . . . . . . . . . . . . 384

4.02.04 Tungsten electrodes . . . . . . . . . . 386 4.02.05 TIG torch . . . . . . . . . . . . . . . . . . . 388

4.02.06 Regulator & accessories . . . . . . 391

4.02.07 Preparing the torch . . . . . . . . . . 393

4.02.08 Welding parameters . . . . . . . . . . 394

4.02.09 Welding technique . . . . . . . . . . . 395


4.02.11 Rods and Flux for TIG welding 400

4.03 Wire Welding . . . . . . . . . . . . . . . . . . . . . . 403

4.03.01 Introduction . . . . . . . . . . . . . . . . . 404


4.03.03 Shielding gas . . . . . . . . . . . . . . . . 411

4.03.04 Equipment . . . . . . . . . . . . . . . . . . 412

4.03.05 Speedweld-160 . . . . . . . . . . . . . . 414

4.03.06 SC 12 RC . . . . . . . . . . . . . . . . . . . . 420

4.03.07 Regulator & accessories . . . . . . 426

4.03.08 Application areas . . . . . . . . . . . . 428

4.03.09 Preparation for welding . . . . . . . 429

4.03.10 Welding technique . . . . . . . . . . . 431

4.03.11 Edge preparation . . . . . . . . . . . . 434 4.03.12 Wires for wire welding . . . . . . . 438


8/552


7

5.01.24 Soldering and brazingtechniques . . . . . . . . . . . . . . . . . . 504


5.01.26 Consumables and parameters for brazing . . . . . . . . . . . . . . . . . . 508

5.02 Gas supplies and gas distributionsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511

5.02.01 Introduction . . . . . . . . . . . . . . . . . 512

5.02.02 Argon . . . . . . . . . . . . . . . . . . . . . . 513

5.02.03 Argon-Carbon Dioxide mixture 514

5.02.04 Carbon-Dioxide . . . . . . . . . . . . . . 515

5.02.05 Oxygen . . . . . . . . . . . . . . . . . . . . . 516

5.02.06 Acetylene . . . . . . . . . . . . . . . . . . . 518 5.02.07 Rules & Safety precautions

for handling and use ofGas cylinders . . . . . . . . . . . . . . . . 522

5.02.08 Gas Distribution System for Acetylene and Oxygen . . . . . . . . 524

6 MISCELLANEOUS INFORMATION . . . . . . . . . 529

5.04 International system of units . . . . . . . . . 530

5.05 The Greek Alphabet . . . . . . . . . . . . . . . . . 531

5.06 General conversion factors . . . . . . . . . . 532

5.07 Roman numerals . . . . . . . . . . . . . . . . . . . . 533

5.08 Metric and decimal equivalentsof fractions of an inch . . . . . . . . . . . . . . . 534

5.09 Wire cross section AWG/mm2 . . . . . . . . 534

5.10 Common gauge series for sheet thickness and wire . . . . . . . . . . . . . . . . . . 535

5.11 Physical properties of someelements . . . . . . . . . . . . . . . . . . . . . . . . . . . 536

5.12 Hardness comparison table . . . . . . . . . . 537

5.13 Corrosion of galvanic couples in sea water . . . . . . . . . . . . . . . . . . . . . . . . . . 538

5.14 Temperature scales . . . . . . . . . . . . . . . . . 540

5.15 Pressure variations relatedto temperature . . . . . . . . . . . . . . . . . . . . . 541

5.16 Abbreviations and weldingterminology . . . . . . . . . . . . . . . . . . . . . . . . . 542

4.04 Plasma Cutting . . . . . . . . . . . . . . . . . . . . . 441

4.04.01 Introduction . . . . . . . . . . . . . . . . . 443


4.04.03 Plasma cutting equipment . . . . 446

4.04.04 UPC-838 . . . . . . . . . . . . . . . . . . . . 447

4.04.05 Cutting technique . . . . . . . . . . . . 450

4.04.06 Maintenance andtrouble shooting . . . . . . . . . . . . . 452

4.05 Current Distribution System . . . . . . . . . . 455

5 GAS WELDING AND CUTTING PROCESS & EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459

5.01 Ac/Ox cutting, welding, brazing . . . . . . 461 5.01.01 Introduction . . . . . . . . . . . . . . . . . 462

5.01.02 The Combination Torch UCT-500 464

5.01.03 UCT-500 Components andspares . . . . . . . . . . . . . . . . . . . . . . 466

5.01.04 The Unitor Workshop Cabinet . 468

5.01.05 Welding and grinding goggles 470

5.01.06 Accessories . . . . . . . . . . . . . . . . . 471

5.01.07 Portable gas equipment . . . . . . 472

5.01.08 Gas hoses . . . . . . . . . . . . . . . . . . 475

5.01.09 Hose connectors . . . . . . . . . . . . 478 5.01.10 Gas regulators for cylinders . . . 480

5.01.11 Flashback . . . . . . . . . . . . . . . . . . . 482

5.01.12 Flashback arrestors . . . . . . . . . . 483

5.01.13 The acetylene/oxygen flame . . 484

5.01.14 Operating instructions forUCT-500 cutting torch . . . . . . . . 486

5.01.15 Cutting procedure . . . . . . . . . . . . 488

5.01.16 Common cutting faults . . . . . . . . 490

5.01.17 Operating instructions for

UCT-500 brazing, welding &heating torch . . . . . . . . . . . . . . . . 492

5.01.18 Maintenance of blowpipes . . . . 494

5.01.19 Heating techniques . . . . . . . . . . 496

5.01.20 Flame straightening techniques 497

5.01.21 Welding techniques . . . . . . . . . . 499

5.01.22 Butt joints for gas weldingof steel . . . . . . . . . . . . . . . . . . . . . 502

5.01.23 Consumables and parameters for gas welding . . . . . . . . . . . . . . . . . 503


9/552

8

WELDING HANDBOOK NOTES

1.00


10/552

1.00

SAFETY IN WELDING

9

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

How to use the handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Welding instructions and training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Personal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Work site protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Welding fumes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Safety check list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30


11/552

1.00

SAFETY IN WELDING

10

IntroductionWelding and related thermal proc-esses utilize compressed gas and/or

electric current to provide a con-centrated heat source which meltsor burns away steel and other met-als. Proper safety precautions arerequired to avoid accidents relatedto the gas and power supplies, to thesparks, heat, fumes, and visible andinvisible rays from the heat source.

Authorities in most countries havelaid down regulations and guidelines

related to welding and other hot workprocesses, their application onboardships, the equipment to be used andthe protection of the operator.

These regulations must be availableonboard, and be known and adheredto when hot work is to be done.

A welded component that fails mayrepresent a safety hazard to crew,ship and cargo. Classification soci-

eties and other authorities haveconsequently issued regulations andwelding procedures for a number ofapplications onboard. These shouldbe known and followed whereverapplicable, and welding should be

performed by qualified personnelunder proper supervision.

In this chapter as well as in otherparts of the handbook, you will findguidelines on safe handling ofequipment, how to protect yourself,and safety precautions that should beobserved when welding and relatedthermal processes are used on boarda ship.

You will also find extensive informa-tion on how and where to use filler

materials, and some guidelines as toidentifying metals.

This handbook, however, cannotbe considered to be a completemanual for each of these areas, deal-ing in detail with all the aspects of thevarious items. Additional informationshould be sought in other publicationsfrom Unitor, from Authorities and oth-ers and by attending training courses.

The courses at the Unitor TrainingCentres will deal in detail not onlywith the technique required for a suc-cessful weld, but also with the safetyaspects around welding onboard.

Additional information

should be sought in other publicationsfrom Wilhelmsen Ships Service, from

authorities and others and by attend-ing training courses. Approved Unitorwelding courses will deal in detailnot only with the technique requiredfor a successful weld, but also withthe safety aspects around weldingonboard.

Do not install, operate or repair equipment for weldingor related thermal processes unless you are thoroughlyfamiliar with:

The Instruction Manual for the equipment to be used.

Rules and regulations relating to the handling andinstallation of the equipment.

Rules and regulations relating to hot work onboard.

Proper use of protective equipment and accessoriesrelated to the hot work, like fire extinguishers, fume

extraction equipment, etc. Proper use of the filler material and fluxes for the job.

SAFETY DEPENDS ON YOU


12/552

How to use the HandbookRead this first

Familiarize yourself with the chapter you are now reading, and follow the

advice given here whenever you weld. If you know little about welding and yourobjective is to become familiar with the welding processes on a self-study basis,start with the chapters at the back of the book and follow the processes from gasto flame, from primary power to arc and then through consumables to solutions. If,on the other hand, you have a basic understanding of welding, read the book fromthe beginning, starting with the chapter on solutions.

When facing a problem

Consult the solutions chapter. Here you will find quick guides to cutting,joining, rebuilding and coating, as well as information on how to identify

metals, descriptions of the most common metals, and a number of examples onwelding applications. You will also find tables for calculating filler materialconsumption.

Use the consumables correctly

When a solution is found you should check the specifics of the consuma-bles you are going to use. The descriptions given in the chapter on consumableswill not only give you technical information on the consumables, but also advise ifspecial procedures should be followed for the particular product at hand.

The process

Before commencing work, take the time to check the details of the equip-ment and the technique you should use from the section on processes. You shouldalso read through the special instruction manuals for the process and equipmentyou are going to use.

Power and gas supply

Safe operation and successful results depend on you being familiar withthese chapters, and also the instruction manual on the specific powersource you have onboard. Ensure that the gas supply is in proper order and

correctly maintained, that the welding machine is suited for the process at hand,

and that the cables are of correct size.Cold repair components require no outside energy. The energy is built intothe products and is released when the base and activator is mixed together.

In order for the chemical reaction to take place, the temperature must be above+5C.

The remaining questions

Reading through the handbook you will come across terminology andabbreviations you may not be familiar with. These are explained in an exten-sive Abbreviations and welding terminology section in the Miscellaneous

Information chapter. In this chapter you will also find a number of useful tablesand comparisons.

1.00

SAFETY IN WELDING

11


13/552

1.00

SAFETY IN WELDING

12

Welding instruction and trainingAs the worlds leading welding supplier to the marine industry, Wilhelmsen Ships Service has designed andcertified a number of well recognised welding academies around the world. These academies offer tailor madesolutions for maintenance and repair welding onboard vessels.

It is crucial that pressurised gases and arc welding equipment are handled in a safe and secure way, andsafety related issues are always a top priority for running the vessel. The consequences of not adhering tocorrect safety procedures can be both hazardous for the crew and damaging to the vessel. Therefore, healthand safety issues are an essential and an important part of the welding training offered.

Welding and related processes are complex and require hands-on training, which teaches skills that areotherwise difficult to obtain. By attending the our approved training academies, the vessels crew will becertified and trained to perform quality welding repairs onboard.

Working in the ships operating environment, in awkward positions, and with the numerous kinds of metalsonboard, can be very challenging. These are all elements the crew must take into consideration in order towork effectively. The Wilhelmsen Ships Service approved academies offer both practical and theoretical

training as to how to select the correct welding methods and filler materials. These courses aim to helpshipboard welders overcome the daily maintenance challenges onboard.

In order to meet world fleets logistical time challenges and requirements, we endeavour to offer flexible

solutions, and can therefore arrange courses throughout the year. The pupils can be enrolled and trained atshort notice, and courses may be tailor-made to fit the pupils individual needs.

Over the years, thousands of seafarers have completed our courses, ensuring that high quality workmanship iscarried out onboard the worlds fleets.

The courses offer training in the following processes:

Unitor Welding Centre Oslo, NorwayContact: [email protected]: + 47 67 58 45 50Internet site: www.wilhelmsen.com/shipsservice

Unitor Welding Centre Piraeus, GreeceContact: [email protected]: + 30 210 4239 100

Internet site: www.wilhelmsen.com/shipsservice

International Maritime Training Centre Mumbai, IndiaContact: [email protected]: +91 22 2570 5570Internet site: www.imtcmumbai.org

Norwegian Training Centre Manila, the PhilippinesContact: [email protected]: +632 8120 742Internet site: www.ntcm.com.ph

Maritime Academy of Asia and the Pacific

Bataan, The PhilippinesWelding School I and IIContact: [email protected]: +632 7411 024 loc 4024Internet site: www.maap.edu.ph

Consolidated Training Systems Inc Manila, The PhilippinesContact: [email protected]: + 632 5240 572Internet site: www.compass.com.ph

Marlow Navigation Training Center Inc. Manila, The PhilippinesContact: [email protected]: + 632 981 6682 loc 2128

Internet site: www.mntc.com.ph

Toplis Offshore Training Center Manila, the PhillippinesContact: [email protected]: + 632 523-7070/532-7171Internet site: www.toplistraining.com

University of Cebu Maritime Education Cebu, the PhillippinesContact: [email protected]: Tel. 032 255 7777 loc 103/Tel. 032 255 7777 loc 139Internet site: www.uc.edu.ph

Stick electrode welding TIG (Tungsten Inert Gas) welding MIG (Metal Inert Gas) welding MAG (Metal Active Gas) welding Plasma cutting Gas welding, brazing, soldering and cutting Cold repairs using cold repair components

Materials: Steel Stainless Steel Copper and copper alloys Cast iron Cast steel Aluminium

Throughout the years thousands of seafarers have completed our courses, ensuring that good qualityworkmanships is carried out onboard the worlds fleet.

To sign up or to obtain more information please contact your local Wilhelmsen Ships service office or the belowacademies.


14/552

1.00

SAFETY IN WELDING

13

Personal protectionWhy do you need protective equipment?

Protection against electric shocks Electric shocks can be the cause of two types of accidents:

Direct accidents caused by the shock itself can be anything fromminor burns to heart failure.

Indirect accidents caused by falls from scaffolding and platforms.

Protection against burns

Burns may be caused by hot work pieces, sparks, molten metal, red-hotelectrodes etc.

Protection against ultraviolet and infrared light Many welders have experienced the discomfort of arc-eye or sun-

burnt skin on unprotected parts of the body, usually due to insufficientor incorrect protective equipment.

Protection against chemicals

Most of the products in the Unitor Cold Repair Component range are tobe considered harmless. Nevertheless we always recommend that onedoes the mixing and application in a ventilated area and always wearthe gloves supplied with the set, when handling polymer products.

Protection against flying chips

When using a chipping hammer to remove slag from the weld, there is alwaysa risk of flying chips which are a potential danger. The chips are sharp and cancause serious damage to the eyes.

General body protection

A welder at work is isolated from his surroundings. He must concentrate on thewelding operation and cannot see what may be happening in the surroundingarea. He must therefore always wear a safety helmet, safety shoes etc. whichwill offer him protection against accidents beyond his control.

A welder must always use complete personal protection equipment butit is also important that he uses the correct type of equipment for the job.Wilhelmsen Ships Service, who supply a full range of welding equipment allover the world, can offer correct and complete protection equipment which willprovide maximum safety for the welder in all situations.

Work site protection

In order to protect the surrunding area from sparks and spatter, ultra violet andinfrared light, welding curtains and/or blankets should be used.


15/552

1.00Arc welding face shields and glassesA welder should bear in mind that proper protection is absolutely necessary toguard himself against the danger of electric shocks, burns, ultra-violet rays andbits of welding slag in the eye.

Unitor face shields for welding are made from a lightweight, robust plasticmaterial which is unaffected by heat, cold or moisture, and both glasses andshields conform to relevant EN standards.

The Autovision Plus Fresh Air Welding Shield

This Shield is the AutoVision Plus with respiratory unit. It gives the userclean, filtered air inside the helmet, and prevents inhalation of welding

fumes. The airflow will keep the user fresh and let him concentrate onthe work. The kit is CE approved and conforms to EN 12941-TH2P.

The fan battery recharges in 2-4 hours and will provide up to 220 litersper minute for at least 8 hours.

The AutoVision Plus Welding face shield

The basis is a lightweight well designed shield which allows good airflow for the welder, and a head band that allows unique possibilities

for adjustment: Distance to face Angle in relation to face Height on head Head diameter Stay-up friction

Replaceable inside and outside protective lenses, headband and sweatband forthe headband is available as spares. The shield is equipped with a light poweredquick automatic darkening glass that switches from low shade (4) to selected

shade within to selected dark state within 0,4 milliseconds (0,0004 sec)The lowshade state allows for good vision while chipping slag, grinding and repositioningfor next arc striking.Dark mode is adjusted with a knob at the side of the shield,from shade 9 to 13 which is from the lowest TIG welding settings (5-10A) toextreme processes at + 400A arc current.

The Flip-Vision Welding face shield

This is the AutoVision face shield with headband where the AutoVision cassetteis replaced with a flip-up front frame. A clear safety glass is placed in the fixed

frame under the flip-up frame protecting the eyes when chipping slag. The flip-upfront frame is fitted with a filter shade glass with shade selected according to

SAFETY IN WELDING

14

The AutoVision Weldingface shield

Fresh air kit for face shield


16/552

welding current used. The filter shade glass isprotected against spatter by a clear protectionglass fitted in front of it. Shade 11 glass issupplied as standard with the shield. Theglasses have dimension 60 x 110 mm.

Safety helmet with face shield

The Flip-Vision face shield is also available withsafety helmet instead of headband.

Face Shield with handle

The face shield withhandle is also suppliedwith shade 11 darkglass and clearprotection glass asstandard. It is designedto also protect thehand holding it fromradiation.

1.00

SAFETY IN WELDING

15

Safety helmet w/face shield

Face shield w/handle

Face shields

Description Product no.

Autovision Plus FreshAir Weldshield with respiratory unit 196 767000

AutoVision Plus Welding Face Shield with Adjustable Shade 9 To 13 196 767001

FlipVision shield with flip-up frame, head band and shade 11 glass 196 709485

Safety helmet with face shield, flip-up front frame and shade 11 glass 196 619114

Face shield with handle and filter shade 11 glass 196 619098

Spares for AutoVision Plus

Autovision Plus Outside Cover Lens10 pcs and 2 frames 196 766997

Autovision Plus Headband complete with nuts and bolts 196 766998

Autovision Plus FreshAir Headgear without hose and fan 196 766999

Autovision Plus FreshAir Face seal with attachment screws 196 767002

Autovision Plus FreshAir Filter 196 767003

Spares and accessories for Autovision (old model) and Flipvision

Autovision Outside Cover Lens 10 pcs 112 X 93mm 196 709469

Autovision Inside Cover Lens 10 pcs 97 X 47mm 196 709477

Headband Complete For Autovision 196 709493

Sweat Band For Autovision 196 709501

The Flip-Vision Weldingface shield


17/552

1.00

SAFETY IN WELDING

16

Glasses for Arc Welding

The glasses have dimension 60 x110 mm and are manufactured in

accordance with DIN standard andare CE approved. When ordering faceshields, filter shade glass of correctshade should be ordered in additionto the filter shade 11 glasses which isincluded.

The filter glasses are supplied insets consisting of 5 safety glasses, 5protection glasses and 5 filter shadeglasses.

Items to be mounted into Unitor faceshield in the following manner:

A. Safety glass (Polycarbonate)

The glass should be placed near-est to the eyes to protect againstslag or other particles while chip-

ping/grinding. When using a shieldwith a flip-up front frame, thesafety glass shall be placed in thefixed frame.

B. Filter shade glass

Filters out harmful infra-red andultra-violet rays from the weldingarc, and reduces visible light to alevel which is sufficient to see thewelding process without strainingthe welders eyes. Filter ShadeGlass should be selected afterconsulting the welding processand amperage (see table). Theglasses are marked Protane ShadeSO 1 DIN 0196 CE

C. Protection glass

Is placed in front of the filter shadeglass to protect against spatter.

The protection glass should bereplaced at regular intervals.

A B C

Guide to arc welding glasses

Amperage Filter Quantity ProductShade in number

Unit unit

< 20 A 89 5 sets 196-633230

2040 A 910 5 sets 196-633248

4080 A 10 5 sets 196-633255

80175 A 11 5 sets 196-633263

175300 A 12 5 sets 196-633271

300500 A 13 5 sets 196-633289

Safety Glass 10 pcs 196-633222

Protection Glass 10 pcs 196-633214


18/552

1.00


17


19/552

1.00

SAFETY IN WELDING

18

Safety goggles clear for eyeprotection

Comfortable protective spectacles

with integrated side guards. The lensis made of scratch-resistant anti glarematerial. The temple arm length andangle is adjustable. For use duringdaily maintenance work in workshopand on site for protection againstflying objects. The spectacles (1 pair)are supplied with cord and protectivesilk bag which also can be used forcleaning the lenses.

Safety goggles Shade 5 for brazingand welding

Same modern lightweight designand features as the Clear version.Fitted with Shade 5 lens. For use whendoing brazing and light duty gaswelding and cutting work. Not foruse when doing arc welding. Thespectacles (1 pair) are supplied withcord and protective silk bag which also

can be used for cleaning the lenses.

Welding and grinding goggles

Lightweight goggles with soft andcomfortable surfaces against theface. The ventilation slots aredesigned to prevent entry of sparksand spatter, at the same time ensuringsufficient air circulation to preventdampness and fogging of the glasses.

The filter shade glass are mountedin a flip-up front frame. A protectionglass must be placed in front of thefilter shade glass in order to protectagainst spatter. One more protectionglass must be placed in the fixedframe.

Safety grinding goggles

Half mask goggle of clear softsynthetic none-mist material. For

grinding only.

Product Pcs. Product no.

Welding/GrindingGoggles w/flip-up-frame

1 176-175273


Safety Spectacles Clear 1 176-632943


Safety Spectacles Shade 5 1 176-632950


Safety grinding

goggles non mist 1 176-653410


20/552

1.00

SAFETY IN WELDING

19

Guide to gas welding glasses

Application Filter Pcs/ ProductShade set number

Glass

SilverBrazing 3 10 176-633305

Gas Welding& Cutting

5 10 176-633313

General 6 10 176-633321

Gas Welding

& Cutting 7 10 176-633354Thick material

Protection Glass 10 176-633297

Glasses for gas welding and cutting

The Unitor gas welding glasseshave a diameter of 50 mm and fit

the goggles. They are available indifferent grades of shade for varioustypes of work. All glasses come insets of 10 pcs.

A. Protection glass

When using goggles with a flip-up

front frame, the protection glass

should be placed in the fixed

frame.

B. Filter shade glass

In order to filter out the strong

glare of the flame.

A. Protection glass

One protection glass must be

placed in front of the filter shade

glass in the flip-up front frame in

order to protect against spatter.

The protection glass should be

replaced at regular intervals.

A B A

Items to be mounted into Unitor faceshield in the following manner:


21/552

1.00

SAFETY IN WELDING

20

Welders protective clothing

Made from specially treated leather,these protective clothes are heat andwear resistant. They provide protec-tion during welding, especially whenthe welder has to work close to theworkpiece or where movement is

restricted. It is specially importantthat the welding jacket is worn whenwelding overhead, to protect the bodyand arms against falling sparks andslag.

In addition to protection againstsparks and molten metal, the taskof the protective leather clothing isalso to protect against electric shock.When dry the leather acts as an elec-

tric insulator. Therefore always weardry protective clothing when doingarc welding.

C

A

D

H

F

E

B

G

I

Pos. Product Pcs/set Product no.

A Welders gloves for electric arc welding 6 pairs. 196-632786

B TIG and gas welding gloves 6 pairs. 196-632794

Working gloves 12 pairs 196-633057

C Leather jacket, Large for welding pcs 196-510438

C Leather jacket, Extra large for welding pcs 196-510446

D Leather trousers with belt pcs 196-633016

E Leather cuffs pair 196-175935

F Arm protector pair 196-184184

G Leather apron pcs 196-510420

H Leather spats pair 196-510453

I Electrode quiver for max 2 kg electrodes pcs 196-633040

Heat resistant mitten pcs 176-233148

Protective clothing


22/552

1.00

SAFETY IN WELDING

21

Electric arc welding gloves

Gloves must always be worn whenarc welding. Special welding gloves

with long gauntlets are necessary.These must be of leather.

Long lined welding gloves arerecommended for welding withcoated electrodes.

TIG and Gas welding gloves

Thick welding gloves will hamper thecontrol of the torch or rod. Specialsoftskin gloves are available for this

purpose. They will protect fully fromsparks and the radiation from an arc,but will give less protection than thethicker welding gloves when touchinghot metal.

Heat resistant mitten

This is a special mitten with a heatand fire resistant woven kevlar outerlayer, and further insulation againstheat in the inner layers. It is designed

to make it possible to close an acety-lene cylinder valve even if the escap-ing gas is on fire, and should alwaysbe kept by acetylene cylinders as asafety precaution. It is also suitablefor handling hot work pieces.

Working gloves

This type of glove is not designedfor hot work; just for handling of

equipment and consumables.


23/552

1.00

SAFETY IN WELDING

22

Work site protectionWelding Curtain

The purpose of the Welding Curtain

is to avoid other personnel beingharmed by the welding work takingplace. The curtain blocks out allhazardous ultraviolet and infraredlight from the welding arc, but stillenables one to see trough the curtain.It is made of self-extinguishingmaterial. The size of the curtain is 2m high and 1,3 m wide. The top of thecurtain has 7 holes and the curtain

comes complete with 7 heavy-dutyhooks. With the hooks the curtaincan be put in a frame, or hooked upon an existing pipe or wire. Maximumpipe diameter the hooks will fit on is41 mm. In order for the curtain to bedrawn freely the pipe should be lessthan 30 mm. It is possible to join twoor more curtains together by the useof snap on buttons along the side. Thecurtain with hooks is supplied ina plastic bag. The curtains are inaccordance with EN 1598.

Welding spatter blanket

Non-asbestos woven glass fabricwith a fire retardent weavelock, forprotecting combustible materials anddelicate machinery from spatter andspark during welding and cutting.Available in a roll 1m x 10m. Nom.Thickness 0,82mm. Max operatingtemperature 550 C. The weldingblanket is supplied in a carton box.


Welding curtain w/hooks, orange 1,4 x 2 m

1 196-633065


Welding spatter blanket 1 196-646067


24/552

1.00

SAFETY IN WELDING

23

Always keep a fire extinguisher readywhen welding outside workshop. The

PP3P is a lightweight ABC dry powderfire extinguisher.

Technical Properties

This device was designed usinghighly reliable materials and thelatest corrosion-resisting protectiontechnologies In order to be ideallysuited to the requirements of themaritime environment.

It complies with European AENOR- EN 3 standard, and is of the hightestperformance in its category.

Efficiency

Classes A, B or C

The multi-purpose nature of the ABCpowder extinguisher ensures that itis effective against these three typesof fire. For solid material fires (class

A), it replaces the conventional waterproducts, which are sometimes notrecommended for use with electricalcurrents. For liquid, liquefiable solidand gas fires, it acts in the sameconditions as the BC powder and isideally suited for Industrial hazards.

Extinction Mechanism

The multi-purpose ABC powder acts:-on the flames, by negative catalysis,-on the embers, by cooling andforming a layer of heat insulating andfireproof varnish, which coats thefire, preventing it from re-igniting.

When sprayed, the ABC powder formsan insulating screen, which protectsthe user from heat radiation.

Easy to use

0peration

Once the safety pin has beenremoved, the device is pressurised by

Instructions for use

Weight: 4,7 kg.

Temperature limits: -20 C to +60 C

pressing on the striking handle. Theflow rate is controlled by the tap on

the final control valve. The fact that itis so simple to use means that risks ofincorrect use are greatly reduced.


PP3P 1 291-667394

Fire extinguisher


25/552

1.00

SAFETY IN WELDING

24

fumes is kept at a reasonable level.When the base metal has been sur-face-treated, the smoke may containsubstances which could constitutea health risk.

Welding of galvanized materialsor materials surface treated withsubstances containing zinc, givesoff fumes which contain zinc oxide.Inhalation of these fumes can resultin zinc poisoning with very unpleas-ant effects. It should be avoided bythe use of a good extraction unit, orthe use of a face shield with fresh airconnection.

Cadmium plating is sometimes usedinstead of zinc plating. Welding orcutting cadmium-plated material canproduce fumes which contain cad-mium oxide. Lung damage can resultfrom the inhalation of this substance.

When welding or cutting old steelplating, remember that the surface

coating may contain lead or mercury.Fumes from these substances canresult in serious health damage ifinhaled.

When welding or cutting any typeof material that has been plated orsurface coated, precautions mustbe taken against dangerous fumesbefore welding commences.

Welding of stainless or acid-resist-

ant steel produces smoke containingnickel and chrome. Copper alloys (tinbronze, leaded gun metal, leaded tinbronze and brass) contains items suchas tin, zinc, lead, etc. Welding temper-ature tends to vaporise these items.Inhaling these substances can seri-ously affect the respiratory system.

When weIding these types of steel ormaterials plated or coated with sub-

stances containing chrome, cadmium,nickel lead or mercury, it is essential

Welding fumesWelding fumes, or smoke consistsof a mixture of gases and dust par-

ticles. The composition of the fumesdepends on:

1. The filler material and method ofwelding.

2. The base material.

Different welding methods and dif-ferent metals, means that the fumesgiven off may contain numerous com-ponents which can be dangerous if

inhaled. The best protection is the useof a smoke extraction unit. When cor-rectly positioned, this unit will protectthe welder against fume inhalationand also prevent the smoke spreadingin the surrounding area and contami-nating the area for others.

If it is not possible to use a smokeextraction unit, the welder can mini-mize the risk of fume inhalation by

positioning himself so that the smokerises some distance from his noseand mouth or by using a welding faceshield with fresh air supply. For onboard use a self contained unit withfilter is a safe and flexible solution.

Electric arc welding with coated elec-trodes, may comprise several differentcomponents depending on the typeof electrode. The composition of the

smoke will therefore vary dependingon the type of electrode. Electrodesare divided into smoke classes 1 to 7,which indicates the degree of smokepollution. See the Coated Electrodessection on smoke classes.

Risks

The fumes given off when weldingunalloyed or low-alloyed steel whichhas not been surface treated, are not

considered to be particularly danger-ous as long as inhalation of these


26/552

1.00

25

SAFETY IN WELDING

that a smoke extractor unit is used. Ifthis is not possible, the welder mustbe equipped with, and must use aface shield with fresh air connection.

Welding, cutting and brazing with agas torch can produce smoke whichmay contain several toxic substances.Of the gases given off, it is primarilythe nitrous gases (NO2+ NO) that are

a health hazard. The amount of nitrousgases in the smoke depends on sev-eral conditions. The use of large sizetorches in confined spaces can quick-

ly produce dangerous concentrations.No warning is given of the presenceof these gases in the form of irritationof the muceous membrane in eyes,nose or throat. Proper ventilation mustbe arranged, and when working inconfined spaces, the welder must notleave the torch alight when he is notactually using it.

Carbon monoxide may be given off due

to incomplete combustion of the gasesor if the material being welded or cutis plastic surfaced, varnished, paintedor oily. High concentrations, whichconstitute a health risk, can be formedin confined spaces, tanks, pipes etc.Inhalation of large quantities of carbonmonoxide can lead to suffocation.

This section points out some of themore usual risks connected with weld-

ing smoke. There are special books onthe subject, and welding smoke is alsoundergoing continuous research. Theresult of this research work may bringnew important factors to light and allthose involved in welding should keepthemselves informed of the develop-ment in this area, so precautions canbe taken to protect against health riskswhich may, as yet, be unknown.

Avoid direct inhalation of welding fumes.

Use fume extraction.

Use Fresh Air supply.


27/552

1.00

SAFETY IN WELDING

26

Welding fumes

All Unitor Electrodes are issued a fume Class number according to Danishstandard. These are the recommended precautions .

Fume Class 1: Ensure sufficient ventilation when welding in confinedspaces. Other protective measures are normally not neededin larger well ventilated spaces.

Fume Class 2: Spot extraction is always recommended when welding inconfined spaces. Larger spaces shall be well ventilated.

Fume Class 3: Spot extraction is recommended when welding indoors.Special protective measures are normally not neededoutdoors if there is enough wind or draught to keep fumesand gases from the welders breathing zone.

Fume Class 47: Spot extraction shall be used when welding indoors. Foroutdoor welding see Fume Class 3.

The standards state the connection between Fume Class and NHL* that is atheoretical value to describe the amount of fresh air needed to dilute the fumesto "safe" concentrations. It is important to understand that NHL* is a theoreticalvalue and should not be used for calculating ventilation capacities:

Fresh air needed to dilute the fumes

Fume Class NHL* (m

3

/h) 1 0 100000

* NHL = Nominelt hygenisk luftbehov i m3/t Nominal hygene air supply in m3/h


28/552

1.00

27

SAFETY IN WELDING

FumeClean 230 welding fumeextractor

With this unit a welder is easily protectedagainst inhaling welding fumes that might haveharmful effects. It is compact and lightweightand can be used anywhere a welder can work.

Four-stage filtration system

When the welding fumes enter the unit they firstpass a metal pre-separator, then the fumes flowthrough a aluminium pre-filter and into the mainfilter which has a total area of 12m2. The largearea of the main filter provides a long life anda constant high efficiency since filter cleaningdoes not have to take place very frequently.

The last stage is a High Efficiency ParticleArrestor HEPA 12 which guarantees a filtrationefficiency of 99.9% under all circumstances.

Active carbon filter

If required an optional activated carbon filtercan be placed on top of the main filter to removesmell. It is also possible to add hoses on theexhaust side to completely remove the filtered airfrom the area if required.

Two powerful motors

The two motors guarantee an adequate extrac-tion capacity under all conditions. At low welding

fume concentrations, the extraction capacity canbe halved, in which situation both motors oper-ate at half speed, thus providing a lower noiselevel and reduced maintenance.

Automatic start

When the welding cable is placed in a slit on topof the unit the automatic start/stop function canbe used and the unit will automatically switch onwhen welding starts and off when welding stops.


29/552

1.00

Technical Data

Number of motors 2

Motor power consumption 2x1kW

Power supply 1phase 230V 50/60Hz

Noise level 70dB

High vacuum suction 22 000 Pa

Extraction volume speed settinglow

140 m3/h

Extraction volume speed settinghigh

230m3/h

Filter surface main filter 12 m2

Filter surface HEPA filter 0,4 m2

Filter efficiency incl. HEPA filter 99,9%

Min. operating temperature 5C

Max. operating temperature 40C

Max. relative humidity 80 %

IP class 50

Net weight 16 kg

Ordering informationDescription Product no.

FumeClean 230 complete with 2,5 mhose and nozzle with magnet foot

196 735878

Optionals

Bulkhead Bracket 196 740399

Hose Connection Outlet Side 196 740381

Active Carbon Filter 196 740431

Spare parts

Disposable Cartridge Filter 196 740415

High Efficiency Particle Filter H12 196 740423

Funnel Nozzle With Magnetic Foot 196 740373

Extract/Exhaust Hose 2,5 M, 45 mm

196 740449

Connection Piece For Two Hoses

45 mm

196 740456

Carbon Brushes 2 Sets W. Seals230V

196 740407

SAFETY IN WELDING

28

Dimmensions


30/552

1.00

29



31/552

1.00Safety check list for weldingand related processesPreparation for hot-work onboard

should include, without being limitedto the points below:

Equipment

Check that the power sourcefunctions correctly, is correctlyconnected to mains, and that youare familiar with its operation.

Ensure that gas cylinders areproperly secured, in upright

position, and fitted with correctand properly functioningregulators for the gas. Acetyleneand oxygen regulators shall befitted with flashback arrestors.Protect cylinders against heat andmechanical damage.

The valve opening of the acetylenecylinder shall point away fromother compressed gas cylinders,

and a heat resistant mitten shall beavailable.

Hoses shall be in good condition,without leaks or damage, and withcorrect colour coding for the gas.(Red for acetylene, blue for oxygen,black for shielding gases and filt-ered air). Use correct hose conn-ectors and hose clamps. Pieces ofpipe and twisted wire must never

be used. Never use oil or grease inconnection with welding gases andnever use copper in connectionwith acetylene.

Cables shall be of oil resistanttype with undamaged insulationand properly mounted cableconnectors. Use safety cableconnectors where both halves areprotected to prevent contact with

deck when disconnected.

SAFETY IN WELDING

30

Keep your welding equipment wellmaintained.

Never use defective welding cables.


32/552

1.00

SAFETY IN WELDING

31

Keep cables and hoses clear of passageways.

Place return clamp (return clamp) directlyon the work piece, know where the returncurrent goes.

Check that torches and electrodeholders are in good working order,including check of blowpipes(AC/ OX), nozzles (AC/OX, FlameSpray, TIG, Plasma), electrodes(TIG, Plasma), and insulation (TIG,Plasma, GMAW, MMAW).

Check all gas connectors for leaks,including torch valves. Even Argonmay be a safety risk if it replacesair in a confined area due toexcessive leaks. Replace defectivegaskets with original gaskets only.

Keep hoses and cables clear of passage ways andprotected from sparks, hot metal and mechnicaldamage e.g. in doorways, hatches, etc.

Both welding and return clamp cables should bestretched to the work place, and the return clampshould be fastened with good electrical contactdirectly on the work piece.

Work place

Tidy up the work place and remove any flammable

materials, liquids and gases from workplace and adja-cent spaces including spaces above/below decks,behind bulkheads and inside pipes or containers. Coverany openings through which sparks may be led to otherareas onboard which have not been prepared for hotwork.

Shield the work place to protect others from sparksand radiation from the arc, and post a warning signthat welding is in progress.

Ensure that sufficient and correct fire fightingequipment is available at the workplace, and thatpersonnel familiar with its use is present. Ensure thatthe work place is properly ventilated, if necessarywith special fume extraction equipment. This isespecially important when working on galvanized orcoated surfaces which may produce harmful fumeswhen heated.


33/552

1.00

Hot work procedure

Ensure that all relevant check lists, certificates and

permits for hot work have been issued.

If work is being done outside the ships workshop, anassistant protected in the same manner as the weldershould accompany him.

If work has been done inside a confined space theassistant should be placed outside, within view of thewelder and with possibility to cut off gas and powersupply. (Gas quick couplings and an unlocked safetycable connector may act as emergency cut-offs).

Operator / assistant protection When working, wear safety shoes and a proper boiler

suit with long sleeves. Do not wear clothes of highlycombustible materials or wet clothes, and do not carrycombustible material, e.g. matches, lighters, oily rags.

Welding gloves should always be used, and whennecessary also use additional leather clothing forprotection against sparks, heat and electric shock.

Use head and face protection (helmet, shield,

goggles). Ensure that filter glasses are unbroken andhave the correct shade.

SAFETY IN WELDING

32

Cover openings! Sparks may travel far!

Ensure proper ventilation.


34/552

1.00

SAFETY IN WELDING

33

For light duty work (200 Amps or lower) Working overall w/long sleves (flame

retardent material). Preferably withouttoo many pockets that easily catchsparks. For same reason avoid zips.Avoid synthetic materials, includingnylon, rayon and polyester.

Safety boots with steel toes. Face shield w/handle or face shield w/

head band Welders gloves

For heavy duty work (above 200 Amps) Working overall Safety boots with steel toes Face shield w/head band Welders gloves Leather jacket Leather trousers

For work in vertical and overhead position Working overall Safety boots with steel toes. Face shield w/head band Welders gloves Arm protector Leather spats

Where necessary use a fresh air unit or breathing

apparatus to avoid inhaling fumes and dust from thewelding process.

Never use acetylene or oxygen to blow away dustfrom yourself or the workplace. Always keep dry andkeep the workplace dry, especially when arc welding.

When work is paused or completed

Always remove coated electrodes from the electrodeholder and switch/close off gas and current at thesource (welding machine, cylinder valve, gas outlet)

also during short breaks for meals etc. Do not leave the workplace unattended. When hot

work is completed the work place shall be inspectedat regular interval to ensure that no risk of fireremains. Only when this has been assured shouldfire fighting equipment be retumed to its normalstoring place.

Available wall chart:ID No. 811053 Rev. No. 02 A3 Wall Chart SafetyChecklist for Welding and Related ThermalProcesses.


35/552

1.00


34


36/552

2.01

SOLUTIONS

35

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Quick reference for cutting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Quick reference for joining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Quick reference for rebuilding, hardfacing and coating. . . . . . 43

Quick reference for cold repairs . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Filler material consumption. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Metal identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Unalloyed/low alloyed steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Problem steels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Stainless Steel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Austenitic Stainless Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Ferritic Stainless Steel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Martensitic Stainless Steel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Duplex Stainless Steel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Clad Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Stainless Steel corrosion types . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Storing and handling of Stainless Steel onboard . . . . . . . . . . . . 74

Grinding/cutting consumables for Stainless Steel. . . . . . . . . . . 75

Cast iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Copper and copper alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Aluminium brass (Yorc albro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Bronze. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Nickel bronzes (Cunifer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Aluminium. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Evaluation of weelds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Typical welding faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Inspection of welded joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Crack detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123


37/552

2.01

SOLUTIONS

36

A successful solution is dependentnot only on choosing the right filler

material, but also on the electricpower and gas supply of correctquality and sufficient quantity butalso that the equipment used is theright one for the job. The overviewon power/gas supply, equipment andprocesses show these relations.

IntroductionThis chapter is intended to be a quickreference for finding alternative

solutions to specific problems,indicating the process and fillermaterial which should be used.

All solutions are linked to one of thesymbols below which relates thesolution to filler material type, processand gas/power supplies.

SYMBOL FILLER MATERIAL PROCESS

AC/OX Cutting

AC/OX Heating

Capillary Brazing Rods AC/OX Brazing

Braze Welding Rods AC/OX Brazing

Gas welding Rods AC/OX Welding

TIG Gas Tungsten Arc Welding

Solid Wire Gas Metal Arc Welding

Flux Cored Wire Flux Cored Arc Welding

Coated Electrodes (Stick Electrodes) Manual Metal Arc Welding

Coated Gouging Electrodes Manual Metal Arc Gouging

Copper Coated Carbon Electrodes Air Carbon Arc Gouging

Plasma Cutting

Cold Repair Compound Cold Repairs

Power Supplies All arc processes

Gas Supplies All processes except coated electrodes and self-shielding fluxcored wire.


38/552

2.01

SOLUTIONS

37

P

0WER

SUPPLY

EQUIPM

ENT

AND

PROCESSES

GAS

SUPPLY

EQUIPM

ENT

AND

PROCESSES

UWR = Unitor Welding Rectifiers (DC)

UWI = Unitor Welding Inverter (DC, portable)UPC = Unitor Plasma Cutter (portable)

UWF = Unitor Wire Feeder (portable, for DC)

UWW = Unitor Wire Welder (portable, for DC)

= Three phase mains connection

= One phase mains connection 16A 230V 50/60Hz

= Welding current distribution with outlet point.

= Gas distribution with outlet point.


39/552

2.01


38


40/552

SOLUTIONS

39

2.01

Comments

A0: Best solution. Thickness limitation aprox. 30mm for portableequipment.

A1: Best, most flexible solution, also for thicker materials, thicknesslimitation 100 mm or 500 mm with optional nozzles.

A2: Good solution. Thickness limitation aprox. 30mm for portableequipment.

B: Good solution for groove preparation, especially in cracks incombination with MMA weldlng.

C: Best method for fast, efficient removal of old welds and weldresidues, and also for large scale groove /crack preparation.

Quick reference for cutting

PROCESS AC/OX MMA ACA Plasma

ALLOY

Mild steel A1 B C A

2

Low alloy/ cast steels A1 B C A2 High alloy/ stainless B C A

0 steels

Cast iron B C A0

Copper

B C A0

with alloys

AluminiumB C A

0with alloys

Consumable Cutting CH-2 ACA Torchparts gouging electrode electrode electrode

nozzles. and nozzle. See AC/OX See coated electrodes and See Plasma process. MMA processes. process.


41/552

METALCunifer

Bronze Yorcalbro Brass Copper Cast IronStainless Problem

Unalloyed/Nickel

Steels SteelsLowalloyed/

Alloys Cast Steels

Unalloyed/ Icuni (W) Ialbro (W) Ialbro (W) Ialbro (W) Ialbro (W) Nife (E) 23/14 (E) Tensile (E) LH (E)Lowalloyed/ Tinbro (E) Icuni (W) Icuni (W) Icuni (W) Icuni (W) Nickel (E) Tensile (E) Impact (E) LHV (E)Cast *) **) Tinbro (E) Tinbro (E) Tinbro (E) Tinbro (E) Tinbro (E) Impact (E) *) **) LHT (E)Steels Albronze (E) Albronze (E) Albronze (E) *) **) Albronze (E) *) LHL (E)

*) **) *) **) *) **) *) **) *) **) ***)

Problem Icuni (W) Ialbro (W) Ialbro (W) Ialbro (W) Ialbro (W) Tensile (E) Tensile (E) Tensile (E)Steels Tinbro (E) Icuni (W) Icuni (W) Icuni (W) Icuni (W) Nickel (E) Impact (E) Impact (E)

*) **) Tinbro (E) Tinbro (E) Tinbro (E) Tinbro (E) *) **) *) *)Albronze (E) Albronze (E) Albronze (E) *) **)*) **) *) **) *) **)

Stainless Icuni (W) AG-60 AG-60 AG-60 AG-60 Tensile (E) 18/8Mo (W)Steels Tinbro (E) AG-45 AG-45 AG-45 AG-45 23/14 (E) 23/14 (E)

23/14 (E) 18/8 (E) 18/8 (E)*) *) Duplex (E)

Iduplex (W)*)

Cast Nickel (E) Tinbro (E) Tinbro (E) Tinbro (E) Tinbro (E) Nife (E)Iron Tinbro (E) Albronze (E) Albronze (E) Albronze (E) Albronze (E) Nickel (E)

Albronze (E) *) **) *) **) *) **) *) **) Tinbro (E)*) **) Albronze (E)

*) **) ****)

Copper Icuni (W) Ialbro (W) Ialbro (W) Icuni (W) Icuni (W)*) Icuni (W) Icuni (W) Tinbro (E) Tinbro (E)

Tinbro (E) Tinbro (E) *) **) Albronze (E)Albronze (E) Albronze (E) *) **)*) **) *) **)

Brass Icuni (W) Ialbro (W) Icuni (W) Ialbro (W)

Tinbro (E) Tinbro (W) Tinbro (E) Tinbro (E)*) Albronze (E) *) **) Albronze (E)

*) **) *) **)

Yorcalbro Icuni (W) Ialbro (W) Ialbro (W)Tinbro (E) Icuni (W) *)*) **) Tinbro (E)

Albronze (E)*) **)

Bronze Icuni (W) Ialbro (W)Tinbro (E) Tinbro (E)*) **) Albronze (E)

*) **)

Cunifer Icuni (W)Nickel *)Alloys

2.01

SOLUTIONS

40

Quick reference for joiningThe table on the next pages willsuggest some solutions for joining

metals. Each possibility has itsadvantages and limitations, andfurther information will be foundin this chapter under the metal inquestion, and under each of the fillermaterials.

You should also note that with theTIG (GTAW) arc or the gas flame it isfully possible to join metals withoutadditional filler material when the

material thickness is small and thejoint is suited for it, e.g. welding

outside corners in sheet metalconstructions.

How to use the table:

The metals are found both in the tophorizontal row and in the left verticalcolumn. The possibilities of joiningone metal to another are found on thehorizontal/vertical line connecting themetal through the diagram, as shownfor stainless steel below. The cornerbox (box 7 in the example below)will always show the alternatives for

joining the metal to itself.

Example, joining stainless steel to:

Cunifer/nickel alloys. . . . . . . . . . . . box 1

Bronze: . . . . . . . . . . . . . . . . . . . . . . . box 2

Yorcalbro . . . . . . . . . . . . . . . . . . . . . box 3

Brass . . . . . . . . . . . . . . . . . . . . . . . . . box 4

Copper. . . . . . . . . . . . . . . . . . . . . . . . box 5

Cast iron . . . . . . . . . . . . . . . . . . . . . . box 6

Stainless steel . . . . . . . . . . . . . . . . . box 7

Problem steels . . . . . . . . . . . . . . . box 8

Low alloy steels. . . . . . . . . . . . . . . . box 9

Full scale table overleaf


42/552

2.01

SOLUTIONS

41

META

L

Cunifer

Bronze

Yorcalbro

Brass

Copper

CastIron

Stainless

Problem

Unalloyed/

Nickel

Steels

Steels

Lowalloyed/

Alloys

CastSteels

Unalloyed/

Icuni(W)

Ialbro(W)

Ialbro(W)

Ialbro(W)

Ialbro

(W)

Nife(E)

23/14(E)

Tensile(E)

LH(E)

Lowalloyed/

Tinbro(E)

Icuni(W)

Icuni(W)

Icuni(W)

Icuni(W)

Nickel(E)

Tensile(E)

Impact(E)

LHV(E)

Cast

*)**)

Tinbro(E)

Tinbro(E)

Tinbro(E)

Tinbro

(E)

Tinbro(E)

Impact(E)

*)**)

LHT(E)

Steels

Albronze(E

)Albronze(E)Albronze(E)*)**)

Albronze(E)*)

LHL(E)

*)**)

*)**)

*)**)

*)**)

*)**)***)

Prob

lem

Icuni(W)

Ialbro(W)

Ialbro(W)

Ialbro(W)

Ialbro

(W)

Tensile(E)

Tensile(E)

Tensile(E)

Steels

Tinbro(E)

Icuni(W)

Icuni(W)

Icuni(W)

Icuni(W)

Nickel(E)

Impact(E)

Impact(E)

*)**)

Tinbro(E)

Tinbro(E)

Tinbro(E)

Tinbro

(E)

*)**)

*)

*)

Albronze(E

)Albronze(E)Albronze(E)*)**)

*)**)

*)**)

*)**)

Stainless

Icuni(W)

AG-60

AG-60

AG-60

AG-60

Tensile(E)

18/8Mo(W)

Steels

Tinbro(E)

AG-45

AG-45

AG-45

AG-45

23/14(E)

23/14(E)

23/14(E)

18/8(E)

18/8(E)

*)

*)

Duplex(E)

Iduplex(W)

*)

Cast

Nickel(E)

Tinbro(E)

Tinbro(E)

Tinbro(E)

Tinbro

(E)

Nife(E)

Iron

Tinbro(E)

Albronze(E

)Albronze(E)Albronze(E)Albronze(E)Nickel(E)

Albronze(E)*)**)

*)**)

*)**)

*)**)

Tinbro(E)

*)**)

Albronze(E)

*)**)****)

Copper

Icuni(W)

Ialbro(W)

Ialbro(W)

Icuni(W)

Icuni(W)

*)

Icuni(W)

Icuni(W)

Tinbro(E)

Tinbro

(E)

Tinbro(E)

Tinbro(E)

*)**)

Albronze(E)

Albronze(E

)Albronze(E)

*)**)

*)**)

*)**)

Brass

Icuni(W)

Ialbro(W)

Icuni(W)

Ialbro(W)

Tinbro(E)

Tinbro(W)

Tinbro(E)

Tinbro(E)

*)

Albronze(E

)*)**)

Albronze(E)

*)**)

*)**)

Yorca

lbro

Icuni(W)

Ialbro(W)

Ialbro(W)

Tinbro(E)

Icuni(W)

*)

*)**)

Tinbro(E)

Albronze(E

)

*)**)

Bronz

e

Icuni(W)

Ialbro(W)

Tinbro(E)

Tinbro(E)

*)**)

Albronze(E

)

*)**)

Cunifer

Icuni(W)

Nicke

l

*)

Alloys

Quic

kreferenceforjoinin

g

E

=Coatedelectrode

W

=Weldingwire/rod

*)

AlsocapillarybrazingwithAG-60andAG-45(AG-60onlyforYorcalbro).

**)

AlsobrazingwithFC-bronze(Bronze)orFC-Wearbroforsurfacing.

***

)ForunalloyedsteelMSwire,andc

oatedelectrodesGPO,

GPR,

SPECIAL

andGPRareadditionalalternatives.

***

*)CastIroncomponentsthatmaybe

heatedevenlymaybebrazewelded

withFC-Castiron.

Alu

miniumwelding:Coatedelectrode:

Alumin

WeldingWire:

Alumag


43/552

2.01


42


44/552

2.01

SOLUTIONS

43

The table shows all the possibilitieswithin the Unitor range of filler

materials for the applications listed.The various filler materials have

specific advantages or limitations,and further information will be found

under each of the filler materials.

Quick reference for rebuilding, hardfacing and coating

Examples of applications

Wearmax (E)Tensile (E)

FC-Wearbro (B)

FC-Wearbro (B) Tensile (E)FC-Wearbro (B)

Impact (E)

Tensile (E)Impact (E)

Impact (E)

Wearmax (E)Tensile (E)

Abratech-330 (E)

Chain, rope, wire drum

Spark proof overlay on tools

Rebuilding edges on butterfly

valve

Building up machine parts

Rebuilding gear teeth

Rebuilding valve closing sur-

faces

Rebuilding valve seats onexhaust valves

Spot welds on ladder steps Cargo grab teeth


45/552

2.01

SOLUTIONS

44

Quick reference for rebuilding, hardfacing and coating

Property Rebuilding with Rebuilding with Rebuilding with approx. base improved wear improved

Base material resistance corrosion material properties resistance

Unalloyed/ IMS (W) Wearmax (E) Wearmax (E)low alloyed LHT (E) Impact (E) Tensile (E)cast steels LHR (E) Tensile (E) 23/14 (E)

LHL (E) Abratech-330 (E) Duplex (E) GPR (E) FC-Wearbro (B)* FC-Wearbro (B)*

Problem Tensile (E) Abratech-330 (E) Wearmax (E)

steels Wearmax (E) Impact (E)Impact (E FC-Wearbro (B)*

FC-Wearbro (B)*

Cast iron Nife (E) Nife (E) Nickel (E)Nickel (E) Nickel (E) Tinbro (E) Zinc-coat (P) FC-Cast iron (B) FC-Wearbro (B)* Albronze (E) FC-Wearbro (B)*

Stainless 18/8 Mo (W) Tensile (E) steels Duplex (E) 23/14 (E) Impact (E) 18/8 (E) * Wearmax-327 (E)

Copper Icuni (W) Icuni (W) Tinbro (E) Tinbro (E) Albronze (E) Albronze (E)

FC-Wearbro (B) FC-Wearbro (B)

Brass Ialbro (W) Ialbro (W) Tinbro (E) Tinbro (E) Albronze (E) Albronze (E) FC-Wearbro (B) FC-Wearbro (B)*

Yorcalbro Ialbro (W) Icuni (W) FC-Wearbro (B)*

Bronze Ialbro (W) Ialbro (W) Tinbro (E) Tinbro (E) Albronze (E) Albronze (E) FC-Wearbro (B) FC-Wearbro (B)*

Cunifer Icuni (W) Nickel (E)*

Aluminium Alumag (W) Alumin (E)

W = Welding wire/rod

E = Coated electrode

B = Brazing alloy

*) Flame spray powderalloys may be usedon any base material

except pure copper torebuild for wear andcorrosion resistance.Unique surfaceproperties againstmechanical wear areobtainable.See the process and

the description ofthe powder alloysHardalloy, Universalloyand Bronzalloy for fullinformation.


46/552

2.01

SOLUTIONS

45

Quick reference for Cold repairsWhen repairing a base material, always start with considering welding orbrazing techniques. If one or more of the reasons below apply, consider using

polymer.

1. Where there is a need for emergency repairs.

Cold repair compounds require no rigging-up time, and no need for energy in theform of oxygen / acetylene or electricity The energy is built into the consumable(product) and is released when mixing base and activator. The curing time isdown to a few minutes for several of the products.

2. Where hot work like welding is not permitted due to fire / explosion hazard.

Cold repair systems are cold-curing processes. There is no risk of heat ignitionor sparks.

3. Where the base material is not weldable.

Certain casted metal alloys are not weldable due to their chemistry. Sometimeswelding method /equipment / consumable or operator knowledge is notavailable. If the base material is so corroded that there is nothing to weld on, anew part can be casted with the repair compound.

4. Where distortion of base material is unacceptable.

Welding causes expansion and contraction, leading up to distortion of the workpiece.

5. Where there is restricted space.

Polymer products can, if necessary, be injected through small diameter holes.

6. Where specific properties are required.

In many cases polymer compounds have better properties than weld overlays.Specifically, chemical resistance and wear resistant properties are improved.Large surfaces that are worn are also much faster overlaid with polymercompounds than with weld bead overlays.

7. Where you need non-metal repairs.

Cold repair systems offer solutions for rubber gasket repairs or moulding, as

well as solutions for repair or joining of plastics and composite materials.For cold repairs products see, chapter 3 consumables.


47/552

46

2.01



48/552

SOLUTIONS

47

2.02

Filler material consumptionThe tables give approximate welddeposit volume for various joint types.

The steel weight of deposit per meteris also given.

For steel welding wires and rodsthe deposit weight given equals theweight of filler material required.

The approximate deposit weight inkg for aluminium is found by multi-plying the deposit volume by 0.0027.

The approximate deposit weight inkg of copper alloys is found by multi-plying the deposit volume by 0.009.

For coated electrodes the requirednumber of electrodes (for steel) isfound by dividing the deposit weightby the value (number of electrodesper kg. weld metal found in thedata table for each electrode in thefiller material section.

Note that spatter, welding positions

and work routines, e.g. throwing awaylong electrode stubbs, may influenceon the total consumption.

Outside Corner

Plate Section Deposit Deposit thickness size volume weight per m. per m. t V W

mm mm2

cm3

/m kg/m

2 2 3.5 0.03 3 4.5 7.5 0.06 4 8 10.5 0.08 5 12.5 16 0.13 6 18 22 0.17 7 24.5 31.5 0.25 8 32 40.5 0.32 9 40.54 51 0.40 10 50 64 0.50 12 72 93 0.73 15 113 141 1.11 18 162

Documents

The Welding Handbook for Maritime Welders